Method of making an embossed card and an embossed card made therefrom

Abstract

A method of making an embossed card includes: (a) providing a stack which includes a substrate, a first polymeric layer formed on the substrate, a foam layer formed on the first polymeric layer, a non-woven fabric layer formed on the foam layer, and a second polymeric layer formed on the non-woven layer; (b) providing a printed pattern on the second polymeric layer; (c) providing a transparent film on the printed pattern so as to form a multilayer structure; and (d) embossing the multilayer structure so as to obtain the embossed card.

1 . A method of making an embossed card comprising:
 (a) providing a stack which includes a substrate, a first polymeric layer formed on the substrate, a foam layer formed on the first polymeric layer, a non-woven fabric layer formed on the foam layer, and a second polymeric layer formed on the non-woven fabric layer;   (b) providing a printed pattern on the second polymeric layer;   (c) providing a transparent film on the printed pattern so as to form a multilayer structure; and   (d) embossing the multilayer structure so as to obtain the embossed card.   
     
     
         2 . The method of  claim 1 , wherein the substrate is made of polystyrene. 
     
     
         3 . The method of  claim 1 , wherein each of the first and second polymeric layers includes ethylene vinyl acetate copolymer. 
     
     
         4 . The method of  claim 1 , wherein the foam layer is made of a material selected from the group consisting of ethylene vinyl acetate copolymer, polyvinyl chloride, polyethylene terephthalate, thermoplastic polyurethane, and combinations thereof. 
     
     
         5 . The method of  claim 1 , wherein the printed pattern is formed from ink. 
     
     
         6 . The method of  claim 1 , wherein the transparent film is made of biaxially oriented polypropylene. 
     
     
         7 . The method of  claim 1 , further comprising the step of electroplating to attach an electroplated film to the second polymeric layer prior to step (b), wherein the printed pattern is provided on the electroplated film. 
     
     
         8 . The method of  claim 1 , further comprising attaching a sticker to the substrate opposite to the first polymeric layer. 
     
     
         9 . The method of  claim 1 , further comprising attaching a magnetic sheet to the substrate opposite to the first polymeric layer. 
     
     
         10 . The method of  claim 1 , wherein the embossing in step (d) is conducted by using a high frequency embossing machine. 
     
     
         11 . An embossed card comprising:
 an embossed multilayer structure including
 a substrate; 
 a first polymeric layer formed on said substrate; 
 a foam layer formed on said first polymeric layer; 
 a non-woven fabric layer formed on said foam layer; 
 a second polymeric layer formed on said non-woven fabric layer; 
 a printed pattern disposed on said second polymeric layer; and 
 a transparent film covering said printed pattern. 
   
     
     
         12 . The embossed card of  claim 11 , wherein said substrate is made of polystyrene. 
     
     
         13 . The embossed card of  claim 11 , wherein each of said first and second polymeric layers includes ethylene vinyl acetate copolymer. 
     
     
         14 . The embossed card of  claim 11 , wherein said foam layer is made of material selected from the group consisting of ethylene vinyl acetate copolymer, polyvinyl chloride, polyethylene terephthalate, thermoplastic polyurethane, and combinations thereof. 
     
     
         15 . The embossed card of  claim 11 , wherein said transparent film is made of biaxially oriented polypropylene. 
     
     
         16 . The embossed card of  claim 11 , further comprising an electroplated film sandwiched between said second polymeric layer and said transparent layer, and having the printed pattern. 
     
     
         17 . The embossed card of  claim 11 , further comprising a sticker attached to said substrate opposite to said first polymeric layer. 
     
     
         18 . The embossed card of  claim 11 , further comprising a magnetic sheet attached to said substrate opposite to said first polymeric layer. 
     
     
         19 . The embossed card of  claim 11 , wherein said foam layer has a thickness of 2 mm. 
     
     
         20 . The embossed card of  claim 11 , wherein said first polymeric layer has a thickness of 0.4 mm, and said second polymeric layer has a thickness of 0.1 mm.